Camera-based machine and downtime monitoring
Production in numbers.
Video stays on site.
Onsito is camera-based production monitoring for small and mid-sized manufacturers. Cameras above the workstations see when a machine runs, stops or waits for material, and count parts. In the morning you know where production lost time yesterday. A box on your shop floor processes the video, only numbers leave.
Downtime
How much downtime never gets written down.
The shift log catches long breakdowns. Short stops and waiting for material are usually missing from it. Onsito measures all of them, even the two-minute ones.
unrecorded in one shift on one machine: waiting for material at 12:40 and six short stops of 2 to 4 minutes each. Over 20 shifts a month, that adds up to 13 h 40 min.
What you see in the morning
In the morning you know where production stalled yesterday.
Four numbers your ERP does not have: the state of every workstation, parts and cycle time, downtime with a reason, and plan vs actual. They give you availability and performance, two of the three OEE components. In a cloud dashboard and a short email for management.
From Onsito
Subject Morning shift 11 Oct: 93% of plan, Press 2 stood longest (96 min)
- Press 2 · waiting for material · 2×63 min
- CNC 3 · setup40 min
- Press 1 · waiting for material26 min
Waiting for material made up 54% of downtime, mostly between 8:00 and 9:00 and after lunch.
No names. Only workstations and numbers.
How it works
Video ends at the box next to the machine.
The cameras and the Onsito box sit on your shop floor. Only events and numbers cross your company boundary, encrypted and outbound only.
Exactly what crosses the boundary
{ workstation: "Press 2", state: "waiting", from: "08:10:04", to: "08:48:11" }
{ workstation: "Press 2", parts: 1180, cycle_s: 4.1 }
No video, no images, no names.
People and privacy
It watches machines, not people.
Cameras on the shop floor have to get past management, IT, HR and the people on the line. That is why the rules are part of the product.
For people on the line
- The box blurs people before it stores anything.
- No rating of individuals and no link to attendance records.
- Summaries only by machine, line and hour.
For IT
- Video never leaves the company network, not even for model training.
- Nobody can connect to the box from outside, not even us. Data goes to the cloud in one direction only.
- Hardware from non-Chinese manufacturers, software with vetted licenses.
For HR
- You are the controller, we are the processor under an agreement per Article 28 GDPR.
- For the rollout we provide input for the data protection impact assessment (DPIA) and the text of the employee notice.
- The box keeps footage for 90 days, with people blurred. You set the retention period.
Why a camera
Where a camera sees more, and where it does not.
| Capability | Current sensor on the machine | PLC or MES integration | Onsito, camera above the workstation |
|---|---|---|---|
| Knows when a machine runs or stops | |||
| Knows when a machine waits for material | |||
| Counts parts | |||
| Works on old machines without a PLC | |||
| Works at manual workstations | |||
| No changes to the machine or its wiring | |||
| Sees parameters inside the machine (temperature, pressure, alarms) |
Where a camera cannot see, a current sensor can be added on the machine power cable.
How a pilot works
Five steps from the first visit to measured numbers.
You pick the workstations where downtime hurts most. We measure them and at the end show how much time production loses there and why. Then you decide whether to continue.
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01
Site visit
Youa few hours with the production manager
Wepick the workstations
You getthe chosen workstations and a baseline from the shift logs
-
02
Installation
Youaccess to the workstations, power and network
Wecameras, box, setup
You getthe box running on site, we do not touch the machines
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03
Model training
Youyour supervisor labels sample images with us
Wetrain the model on your site
You getthe first shift overview
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04
Measurement
Youthe supervisor adds downtime reasons
Wewatch accuracy and fine-tune
You geta morning report every day
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05
Evaluation
Youa meeting with management
Wecompare with the baseline
You gethow much time production loses and where
Who is behind Onsito
Dan Burian, founder
Short stops and waiting for material never get written down. Onsito measures them.
More than ten years in operations and the systems around them. At Rohlík I launched the Brno operation and twice moved it overnight to a new warehouse, at Woltair I took the warehouse from paper to a system connected to the ERP.
We are starting pilot deployments
Onsito is in development and we are looking for the first plants in Czechia and Slovakia. Message me and we will set up a site visit.
Message me on LinkedInQuestions
What production, IT and HR ask.
Does any video leave the plant?
No. The Onsito box processes the video right on your shop floor and keeps it only locally. Only events and numbers go to the cloud: workstation state, part counts, cycle times and downtime.
Does Onsito need a connection to the machines or a PLC?
No. The cameras are mounted above the workstations and nobody touches the machines. Where a camera cannot see, a current sensor can be added on the power cable. Onsito takes the production plan from your ERP.
Where is the model trained?
Right on your shop floor, on your parts and machines. The images used for training never leave the company.
Do we have to inform employees about the cameras?
Yes. Both the Czech Labour Code (Section 316) and the GDPR require it. For the rollout we provide input for the data protection impact assessment (DPIA) and the text of the employee notice.
Who is the data controller?
You, as the employer. Head The Projects is the processor where it services the box or trains the model on your site, and we sign a data processing agreement with you under Article 28 GDPR.
What if only one operator works at a workstation?
Onsito still measures the machine. Summaries are by machine and hour and are not linked to attendance records or shift rosters.
Who is Onsito for?
For small and mid-sized manufacturers in Czechia and Slovakia. It helps most where there are older machines without PLC data, manual workstations, and downtime logged by hand.
Does Onsito measure OEE?
Onsito measures two of the three OEE components: availability (when a machine runs, stops and why) and performance (parts and cycle time). It does not measure quality, the share of good parts, yet.
How is Onsito different from sensor-based machine monitoring?
Onsito needs no sensor on the machine and no PLC signal. A camera above the workstation also covers manual workstations and can tell that a machine is stopped because it is waiting for material.
Is Onsito an MES?
No. Onsito does not plan production or track orders. It reads the plan from your ERP and compares it with what the line actually produced.
Which ERP does Onsito work with?
Onsito takes the order plan from an export or through the API of your ERP. We set up the connection to your specific system as part of the rollout.
What if the internet goes down?
The box keeps measuring and holds the numbers. It sends them to the cloud dashboard once the connection is back.
Which workstations can Onsito monitor?
Workstations that can be seen from above: presses, CNC machines, welding, manual assembly, packing. How many workstations one camera covers, we determine during the site visit.
How much does Onsito cost?
We prepare a price after visiting your plant. We do not list it on the website.